U.S. patent number 9,871,157 [Application Number 14/591,608] was granted by the patent office on 2018-01-16 for method for producing concentrator photovoltaic unit, production apparatus used in the method, method for producing concentrator photovoltaic module, and production apparatus used in the method.
This patent grant is currently assigned to Sumitomo Electric Industries, Ltd.. The grantee listed for this patent is Sumitomo Electric Industries, Ltd.. Invention is credited to Makoto Inagaki, Takashi Iwasaki, Yoshiki Kuhara, Rui Mikami, Koji Mori, Kazumasa Toya.
United States Patent |
9,871,157 |
Toya , et al. |
January 16, 2018 |
Method for producing concentrator photovoltaic unit, production
apparatus used in the method, method for producing concentrator
photovoltaic module, and production apparatus used in the
method
Abstract
Mutual alignment between a condenser lens and its power
generating element can be performed easily and accurately. This
method for producing a concentrator photovoltaic unit includes: a
first step of emitting linear laser beams respectively toward
incident positions 42 on an incident surface 13f1; and a second
step of performing positional adjustment between a Fresnel lens 13f
and a power generating element part 21, based on positional
relationship between the power generating element part 21 and beam
images respectively formed by the linear laser beams at a time when
the beam images and the power generating element part 21 are seen
along an optical axis S from the incident surface 13f1 side of the
Fresnel lens 13f. Four incident positions 42 in the first step are
set such that at least one pair of beam images, among the beam
images respectively formed by the linear laser beams, cross each
other at an optical axis point S1 of the Fresnel lens 13f when the
power generating element part 21 side is seen along the optical
axis S from the incident surface 13f1 side of the Fresnel lens
13f.
Inventors: |
Toya; Kazumasa (Osaka,
JP), Iwasaki; Takashi (Osaka, JP), Mori;
Koji (Osaka, JP), Inagaki; Makoto (Osaka,
JP), Mikami; Rui (Osaka, JP), Kuhara;
Yoshiki (Osaka, JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
Sumitomo Electric Industries, Ltd. |
Osaka-shi |
N/A |
JP |
|
|
Assignee: |
Sumitomo Electric Industries,
Ltd. (Osaka-shi, JP)
|
Family
ID: |
53495844 |
Appl.
No.: |
14/591,608 |
Filed: |
January 7, 2015 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20150194561 A1 |
Jul 9, 2015 |
|
Foreign Application Priority Data
|
|
|
|
|
Jan 9, 2014 [JP] |
|
|
2014-002754 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L
31/0543 (20141201); H02S 40/22 (20141201); H01L
31/048 (20130101); Y02E 10/52 (20130101) |
Current International
Class: |
H01L
31/054 (20140101); H02S 40/22 (20140101); H01L
31/048 (20140101) |
Field of
Search: |
;250/203.4,204,208.1,239
;126/683,684,698,699,700,704 ;136/243,244,246,259 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Epps; Georgia Y
Assistant Examiner: Williams; Don
Attorney, Agent or Firm: Venable LLP Sartori; Michael A.
Remus; Laura G.
Claims
The invention claimed is:
1. A method for producing a concentrator photovoltaic unit, the
concentrator photovoltaic unit including a condenser lens
configured to concentrate sunlight incident from an incident
surface thereof, onto a power generating element part, the method
comprising: a first step of fixing a plurality of laser beam
sources to the condenser lens at a predetermined distance from the
incident surface; a second step of emitting linear laser beams in
parallel to an optical axis of the condenser lens, respectively
toward a plurality of specific positions previously set on the
incident surface, the linear laser beams being emitted by the
plurality of laser beam sources and forming irradiation spots on
the plurality of specific positions, the plurality of specific
positions being positions except for an optical axis point on the
incident surface; a third step of capturing an image of beams and
the power generating element part, the image being captured through
the condenser lens along the optical axis from the incident surface
side of the condenser lens, the beams respectively formed by the
linear laser beams having passed the condenser lens to be
concentrated toward a focal point of the condenser lens; a fourth
step of performing positional adjustment between the condenser lens
and the power generating element part, based on positional
relationship, grasped through the captured image, between the power
generating element part and linear beam images in the captured
image; and a fifth step of removing the plurality of laser beam
sources, wherein the plurality of specific positions in the first
step are set to positions that allow at least one pair of linear
beam images, among the linear beam images specified in the captured
image, to be beam images of linear laser beams that cross each
other at an optical axis point of the condenser lens, and the
positional adjustment in the third step is performed based on a
positional relationship between the power generating element part
and a cross point where the one pair of linear beam images cross in
the captured image.
2. The method for producing the concentrator photovoltaic unit
according to claim 1, wherein the power generating element part
includes a power generating element, and a secondary condenser lens
configured to receive light concentrated by the condenser lens and
to lead the light to the power generating element.
3. A method for producing a concentrator photovoltaic module, the
concentrator photovoltaic module including: a plurality of power
generating element parts provided in a form of an array; and a
concentrating member in which a plurality of condenser lenses each
concentrating sunlight incident from an incident surface thereof
are formed at positions on optical axes thereof and corresponding
to the power generating element parts, the method comprising: a
first step of fixing a plurality of laser beam sources to at least
two condenser lenses among the plurality of condenser lenses at a
predetermined distance from the incident surface of each of the at
least two condenser lenses; a second step of emitting linear laser
beams in parallel to the optical axis of each of at least two of
the condenser lenses, respectively toward a plurality of specific
positions previously set on the incident surface, the linear laser
beams being emitted by the plurality of laser beam sources and
forming irradiation spots on the plurality of specific positions,
the plurality of specific positions being positions except for an
optical axis point on the incident surface; a third step of
capturing images of beams and the power generating element part
corresponding thereto, the image being captured through the
condenser lens along the optical axis from the incident surface
side of at least two of the condenser lenses, the beams
respectively formed by the linear laser beams having passed at
least two of the condenser lenses to be concentrated toward a focal
point of the condenser lenses; a fourth step of performing
positional adjustment between the concentrating member and the
power generating element parts based on positional relationship,
grasped through the captured images, between linear beam images in
the captured images, and the power generating element part
corresponding thereto; and a fifth step of removing the plurality
of laser beam sources, wherein the plurality of specific positions
in each of the at least two of the condenser lenses in the first
step are set to positions that allow at least one pair of linear
beam images, among the linear beam images specified in the captured
image, to be beam images of linear laser beams that cross each
other at an optical axis point of the condenser lens, and the
positional adjustment in the third step is performed based on a
positional relationship between the power generating element part
and a cross point where the one pair of linear beam images cross in
the captured image.
4. The method for producing the concentrator photovoltaic module
according to claim 3, wherein the first step is performed for each
of four of the condenser lenses respectively positioned at four
corners of the concentrating member having a quadrangular shape, or
for each of four of the condenser lenses respectively positioned at
edge portions at centers of respective sides of the concentrating
member having a quadrangular shape, and positional adjustment
between the concentrating member and the power generating element
parts is performed through the third step.
5. A production apparatus for a concentrator photovoltaic unit, the
concentrator photovoltaic unit including a condenser lens
configured to concentrate sunlight incident from an incident
surface thereof, onto a power generating element part, the
production apparatus comprising: a plurality of laser beam sources
configured to emit linear laser beams in parallel to an optical
axis of the condenser lens, respectively toward a plurality of
specific positions previously set on the incident surface, the
linear laser beams forming irradiation spots on the plurality of
specific positions, the plurality of specific positions being
positions except for an optical axis point on the incident surface,
the linear laser beams being configured to perform positional
adjustment between the condenser lens and the power generating
element part; an image capturing section configured to capture an
image of beams and the power generating element part, and
configured to output the captured image, the image being captured
through the condenser lens along the optical axis from the incident
surface side of the condenser lens, the beams respectively formed
by the linear laser beams having passed the condenser lens to be
concentrated toward a focal point of the condenser lens; and a
positional adjustment section configured to perform positional
adjustment between the condenser lens and the power generating
element part based on positional relationship, grasped through the
captured image, between the power generating element part and
linear beam images in the captured image, wherein the plurality of
specific positions are set to positions that allow at least one
pair of linear beam images, among the linear beam images specified
in the captured image, to be beam images of linear laser beams that
cross each other at an optical axis point of the condenser lens in
the captured image, and the positional adjustment section is
configured to perform positional adjustment based on a positional
relationship between the power generating element part and a cross
point where the one pair of linear beam images cross in the
captured image.
6. A production apparatus for a concentrator photovoltaic module,
the concentrator photovoltaic module including: a plurality of
power generating element parts provided in a form of an array; and
a concentrating member in which a plurality of condenser lenses
each concentrating sunlight incident from an incident surface
thereof are formed at positions on optical axes thereof and
corresponding to the power generating element parts, the production
apparatus comprising: a plurality of laser beam sources configured
to emit linear laser beams in parallel to the optical axis of each
of at least two of the condenser lenses, respectively toward a
plurality of specific positions previously set on the incident
surface of the condenser lens, the linear laser beams forming
irradiation spots on the plurality of specific positions, the
plurality of specific positions being positions except for an
optical axis point on the incident surface, the linear laser beams
being configured to perform positional adjustment between the
condenser lenses and the power generating element parts; image
capturing sections respectively provided at the at least two of the
condenser lenses, each image capturing section configured to
capture, through the condenser lens along the optical axis from the
incident surface side of the condenser lens, an image of beams and
the power generating element part corresponding thereto, and
configured to output the captured image, the beams respectively
formed by the linear laser beams having passed the condenser lens
to be concentrated toward a focal point of the condenser lens; and
a positional adjustment section configured to perform positional
adjustment between the concentrating member and the power
generating element parts based on positional relationship, grasped
through the captured image from each image capturing section,
between linear beam images in the captured image, and the power
generating element part corresponding thereto, wherein the
plurality of specific positions are set to positions that allow at
least one pair of linear beam images, among the linear beam images
specified in the captured image, to be beam images of linear laser
beams that cross each other at an optical axis point of the
condenser lens in the captured image, and the positional adjustment
section is configured to perform positional adjustment based on a
positional relationship between the power generating element part
and a cross point where the one pair of linear beam images cross in
the captured image.
Description
TECHNICAL FIELD
The present invention relates to a method for producing a
concentrator photovoltaic unit to be used in a concentrator
photovoltaic (CPV) which generates power by concentrating sunlight
on a power generating element, a production apparatus used in this
method, a method for producing a concentrator photovoltaic module,
and a production apparatus used in this method.
BACKGROUND ART
Concentrator photovoltaic is based on a structure in which: a
small-sized compound semiconductor element having a high power
generation efficiency is used as a power generating element, and
sunlight concentrated by a Fresnel lens is caused to be incident on
the power generating element (for example, see PATENT LITERATURE
1). A large number of such basic units are arranged in a matrix
shape in one housing, thereby to form a concentrator photovoltaic
module. A plurality of the modules are further arranged, thereby to
form a concentrator photovoltaic panel. By causing this
concentrator photovoltaic panel to perform tracking operation so as
to always face the sun, it is possible to obtain a desired
generated power.
CITATION LIST
Patent Literature
PATENT LITERATURE 1: U.S. Pat. No. 4,069,812
SUMMARY OF INVENTION
Technical Problem
During production of the concentrator photovoltaic module as
described above, it is necessary to perform alignment precisely
such that, on the optical axis of each condenser lens such as a
Fresnel lens, the center of its corresponding power generating
element is positioned.
Mutual alignment between power generating elements and condenser
lenses can be attained by ensuring their mounting accuracy relative
to their common housing, for example. However, only doing this may
allow minute individual differences, which may result in
misalignment between the optical axis of each condenser lens and
the center of its corresponding power generating element. If
misalignment occurs, power generation efficiency is reduced.
The present invention has been made in view of such a situation. An
object of the present invention is to provide a technology which
can realize easy and accurate mutual alignment between each
condenser lens and its corresponding power generating element.
Solution to Problem
A method for producing a concentrator photovoltaic unit being one
embodiment is a method for producing a concentrator photovoltaic
unit, the concentrator photovoltaic unit including a condenser lens
configured to concentrate sunlight incident from an incident
surface thereof, onto a power generating element part, the method
including:
a first step of emitting linear laser beams in parallel to an
optical axis of the condenser lens, respectively toward a plurality
of specific positions previously set on the incident surface;
and
a second step of performing positional adjustment between the
condenser lens and the power generating element part, based on
positional relationship between the power generating element part
and beam images respectively formed by the linear laser beams
having passed the condenser lens to be concentrated toward a focal
point of the condenser lens at a time when the beam images and the
power generating element part are seen though the condenser lens
along the optical axis from the incident surface side of the
condenser lens, wherein
the plurality of specific positions in the first step are set to
positions that allow at least one pair of beam images, among the
beam images at a time when the power generating element part side
is seen along the optical axis from the incident surface side of
the condenser lens, to be beam images of linear laser beams that
cross each other at an optical axis point of the condenser
lens.
A method for producing a concentrator photovoltaic module being one
embodiment is a method for producing a concentrator photovoltaic
module, the concentrator photovoltaic module including: a plurality
of power generating element parts provided in a form of an array;
and a concentrating member in which a plurality of condenser lenses
each concentrating sunlight incident from an incident surface
thereof are formed at positions on optical axes thereof and
corresponding to the power generating element parts, the method
including:
a first step of emitting linear laser beams in parallel to the
optical axis of each of at least two of the condenser lenses,
respectively toward a plurality of specific positions previously
set on the incident surface of the condenser lens; and
a second step of performing positional adjustment between the
concentrating member and the power generating element parts based
on positional relationship, of each of the at least two of the
condenser lenses, between beam images respectively formed by the
linear laser beams having passed the condenser lens to be
concentrated toward a focal point of the condenser lens, and the
power generating element part corresponding thereto at a time when
the beam images and the corresponding power generating element part
are seen though the condenser lens along the optical axis from the
incident surface side, wherein
the plurality of specific positions in each of the at least two of
the condenser lenses in the first step are set to positions that
allow at least one pair of beam images, among the beam images at a
time when the power generating element part side is seen along the
optical axis from the incident surface side of the condenser lens,
to be beam images of linear laser beams that cross each other at an
optical axis point of the condenser lens.
A production apparatus for a concentrator photovoltaic unit being
one embodiment is a production apparatus for a concentrator
photovoltaic unit, the concentrator photovoltaic unit including a
condenser lens configured to concentrate sunlight incident from an
incident surface thereof, onto a power generating element part, the
production apparatus including:
a plurality of laser beam sources configured to emit linear laser
beams in parallel to an optical axis of the condenser lens,
respectively toward a plurality of specific positions previously
set on the incident surface;
an image capturing section configured to capture an image of the
power generating element part side along the optical axis from the
incident surface side of the condenser lens, to output the captured
image; and
a positional adjustment section configured to perform positional
adjustment between the condenser lens and the power generating
element part based on positional relationship, grasped through the
captured image, between the power generating element part and beam
images respectively formed by the linear laser beams having passed
the condenser lens to be concentrated toward a focal point of the
condenser lens, wherein
the plurality of specific positions are set to positions that allow
at least one pair of beam images, among the beam images specified
in the captured image, to be beam images of linear laser beams that
cross each other at an optical axis point of the condenser lens in
the captured image.
A production apparatus for a concentrator photovoltaic module being
one embodiment is a production apparatus for a concentrator
photovoltaic module, the concentrator photovoltaic module
including: a plurality of power generating element parts provided
in a form of an array; and a concentrating member in which a
plurality of condenser lenses each concentrating sunlight incident
from an incident surface thereof are formed at positions on optical
axes thereof and corresponding to the power generating element
parts, the production apparatus including:
a plurality of laser beam sources configured to emit linear laser
beams in parallel to the optical axis of each of at least two of
the condenser lenses, respectively toward a plurality of specific
positions previously set on the incident surface of the condenser
lens;
image capturing sections respectively provided at the at least two
of the condenser lenses, each image capturing section configured to
capture, along the optical axis from the incident surface side of
the condenser lens, an image of the power generating element part
side corresponding to the condenser lens, and configured to output
the captured image; and
a positional adjustment section configured to perform positional
adjustment between the concentrating member and the power
generating element parts based on positional relationship, grasped
through the captured image from each image capturing section,
between beam images respectively formed by the linear laser beams
having passed the condenser lens to be concentrated toward a focal
point of the condenser lens, and the power generating element part
corresponding thereto, wherein
the plurality of specific positions are set to positions that allow
at least one pair of beam images, among the beam images specified
in the captured image, to be beam images of linear laser beams that
cross each other at an optical axis point of the condenser lens in
the captured image.
Advantageous Effects of Invention
According to the present invention, mutual alignment between a
condenser lens and its corresponding power generating element can
be easily and accurately performed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view showing one example of a concentrator
photovoltaic apparatus.
FIG. 2 is a perspective view (partially cut out) showing an
enlarged view of one example of a concentrator photovoltaic
module.
FIG. 3 is a schematic diagram showing a concentrator photovoltaic
unit.
FIG. 4 schematically shows one example of a mounting device for
mounting a lens panel of the module onto a housing.
FIG. 5 shows a state where the lens panel has been lowered by the
mounting device.
FIG. 6 schematically shows a configuration of a position specifying
device disposed above a Fresnel lens.
FIG. 7A shows captured images obtained by a camera part when each
laser beam source part has emitted a linear laser beam, and shows
one example of a captured image when nothing is present on the
optical axis of the Fresnel lens.
FIG. 7B shows captured images obtained by a camera part when each
laser beam source part has emitted a linear laser beam, and shows
one example of a captured image when a power generating element
part is present near the focal point of the Fresnel lens.
FIG. 7C shows captured images obtained by a camera part when each
laser beam source part has emitted a linear laser beam, and shows
the other example of a captured image when the power generating
element part is present near the focal point of the Fresnel
lens.
FIG. 8 shows one example of an aspect where captured images
respectively outputted by the position specifying devices are
displayed on a display section.
FIG. 9A shows another arrangement example of the position
specifying devices.
FIG. 9B shows the other arrangement example of the position
specifying devices.
FIG. 10A shows another examples of incident positions set on the
incident surface of a Fresnel lens.
FIG. 10B shows the other examples of incident positions set on the
incident surface of a Fresnel lens.
DESCRIPTION OF EMBODIMENTS
Description of Embodiments of the Present Invention
First, contents of embodiments of the present invention will be
listed for description.
(1) A method for producing a concentrator photovoltaic unit being
one embodiment is a method for producing a concentrator
photovoltaic unit, the concentrator photovoltaic unit including a
condenser lens configured to concentrate sunlight incident from an
incident surface thereof, onto a power generating element part, the
method including:
a first step of emitting linear laser beams in parallel to an
optical axis of the condenser lens, respectively toward a plurality
of specific positions previously set on the incident surface;
and
a second step of performing positional adjustment between the
condenser lens and the power generating element part, based on
positional relationship between the power generating element part
and beam images respectively formed by the linear laser beams
having passed the condenser lens to be concentrated toward a focal
point of the condenser lens at a time when the beam images and the
power generating element part are seen though the condenser lens
along the optical axis from the incident surface side of the
condenser lens, wherein
the plurality of specific positions in the first step are set to
positions that allow at least one pair of beam images, among the
beam images at a time when the power generating element part side
is seen along the optical axis from the incident surface side of
the condenser lens, to be beam images of linear laser beams that
cross each other at an optical axis point of the condenser
lens.
According to the method for producing the concentrator photovoltaic
unit having the above configuration, when the power generating
element part side is seen though the condenser lens along the
optical axis from the incident surface side of the condenser lens,
at least one pair of beam images cross each other at the optical
axis point of the condenser lens, and thus, the position of the
optical axis of the condenser lens can be recognized.
Thus, in the second step, positional adjustment can be performed
based on the positional relationship between the power generating
element part and the beam images which allow recognition of the
position of the optical axis of the condenser lens at a time when
the power generating element part side is seen along the optical
axis from the incident surface side of the condenser lens. Thus,
alignment between the condenser lens and the power generating
element part can be performed easily and accurately.
(2) In the method for producing the concentrator photovoltaic unit
above, the power generating element part may include a power
generating element, and a secondary condenser lens configured to
receive light concentrated by the condenser lens and to lead the
light to the power generating element. In this case, based on the
positional relationship between the beam images and the secondary
condenser lens, alignment between the condenser lens and the power
generating element part can be performed.
(3) A method for producing a concentrator photovoltaic module being
one embodiment is a method for producing a concentrator
photovoltaic module, the concentrator photovoltaic module
including: a plurality of power generating element parts provided
in a form of an array; and a concentrating member in which a
plurality of condenser lenses each concentrating sunlight incident
from an incident surface thereof are formed at positions on optical
axes thereof and corresponding to the power generating element
parts, the method including:
a first step of emitting linear laser beams in parallel to the
optical axis of each of at least two of the condenser lenses,
respectively toward a plurality of specific positions previously
set on the incident surface of the condenser lens; and
a second step of performing positional adjustment between the
concentrating member and the power generating element parts based
on positional relationship, of each of the at least two of the
condenser lenses, between beam images respectively formed by the
linear laser beams having passed the condenser lens to be
concentrated toward a focal point of the condenser lens, and the
power generating element part corresponding thereto at a time when
the beam images and the corresponding power generating element part
are seen though the condenser lens along the optical axis from the
incident surface side, wherein
the plurality of specific positions in each of the at least two of
the condenser lenses in the first step are set to positions that
allow at least one pair of beam images, among the beam images at a
time when the power generating element part side is seen along the
optical axis from the incident surface side of the condenser lens,
to be beam images of linear laser beams that cross each other at an
optical axis point of the condenser lens.
According to the method for producing the concentrator photovoltaic
module having the above configuration, positional adjustment can be
performed based on the positional relationship between the power
generating element part and the beam images which allow recognition
of the position of the optical axis of the condenser lens. Thus,
alignment between the concentrating member and the power generating
element parts can be performed easily and accurately.
(4) In the method for producing the concentrator photovoltaic
module above, preferably, the first step is performed for each of
four of the condenser lenses respectively positioned at four
corners of the concentrating member having a quadrangular shape, or
for each of four of the condenser lenses respectively positioned at
edge portions at centers of respective sides of the concentrating
member having a quadrangular shape, and positional adjustment
between the concentrating member and the power generating element
parts is performed through the second step.
In this case, alignment between the optical axes of the condenser
lenses and the power generating element parts can be performed by
use of the condenser lenses which are distanced from each other,
and thus, alignment between the concentrating member and the power
generating element parts can be performed more accurately.
(5) A production apparatus for a concentrator photovoltaic unit
being one embodiment is a production apparatus for a concentrator
photovoltaic unit, the concentrator photovoltaic unit including a
condenser lens configured to concentrate sunlight incident from an
incident surface thereof, onto a power generating element part, the
production apparatus including:
a plurality of laser beam sources configured to emit linear laser
beams in parallel to an optical axis of the condenser lens,
respectively toward a plurality of specific positions previously
set on the incident surface;
an image capturing section configured to capture an image of the
power generating element part side along the optical axis from the
incident surface side of the condenser lens, to output the captured
image; and
a positional adjustment section configured to perform positional
adjustment between the condenser lens and the power generating
element part based on positional relationship, grasped through the
captured image, between the power generating element part and beam
images respectively formed by the linear laser beams having passed
the condenser lens to be concentrated toward a focal point of the
condenser lens, wherein
the plurality of specific positions are set to positions that allow
at least one pair of beam images, among the beam images specified
in the captured image, to be beam images of linear laser beams that
cross each other at an optical axis point of the condenser lens in
the captured image.
According to the production apparatus of the concentrator
photovoltaic unit having the above configuration, positional
adjustment can be performed based on the positional relationship
between the power generating element part and the beam images which
allow recognition of the position of the optical axis of the
condenser lens, and thus, alignment between the condenser lens and
the power generating element part can be easily and accurately
performed.
(6) A production apparatus for a concentrator photovoltaic module
being one embodiment is a production apparatus for a concentrator
photovoltaic module, the concentrator photovoltaic module
including: a plurality of power generating element parts provided
in a form of an array; and a concentrating member in which a
plurality of condenser lenses each concentrating sunlight incident
from an incident surface thereof are formed at positions on optical
axes thereof and corresponding to the power generating element
parts, the production apparatus including:
a plurality of laser beam sources configured to emit linear laser
beams in parallel to the optical axis of each of at least two of
the condenser lenses, respectively toward a plurality of specific
positions previously set on the incident surface of the condenser
lens;
image capturing sections respectively provided at the at least two
of the condenser lenses, each image capturing section configured to
capture, along the optical axis from the incident surface side of
the condenser lens, an image of the power generating element part
side corresponding to the condenser lens, and configured to output
the captured image; and
a positional adjustment section configured to perform positional
adjustment between the concentrating member and the power
generating element parts based on positional relationship, grasped
through the captured image from each image capturing section,
between beam images respectively formed by the linear laser beams
having passed the condenser lens to be concentrated toward a focal
point of the condenser lens, and the power generating element part
corresponding thereto, wherein
the plurality of specific positions are set to positions that allow
at least one pair of beam images, among the beam images specified
in the captured image, to be beam images of linear laser beams that
cross each other at an optical axis point of the condenser lens in
the captured image.
According to the production apparatus for the concentrator
photovoltaic module having the above configuration, positional
adjustment can be performed based on the positional relationship
between the power generating element part and the beam images which
allow recognition of the position of the optical axis of the
condenser lens, and thus, alignment between the concentrating
member and the power generating element parts can be performed
easily and accurately.
Detailed Description of Embodiments of the Present Invention
Hereinafter, preferable embodiments will be described with
reference to the drawings.
[1. Configuration of Concentrator Photovoltaic Module]
FIG. 1 is a perspective view showing one example of a concentrator
photovoltaic apparatus. In FIG. 1, a concentrator photovoltaic
apparatus 100 includes a concentrator photovoltaic panel 1, a post
2 which supports the concentrator photovoltaic panel 1 on the rear
surface side thereof, and a base 3 on which the post 2 is
mounted.
The concentrator photovoltaic panel 1 is formed by assembling a
large number of concentrator photovoltaic modules 1M vertically and
horizontally. In this example, 62 (7 in length.times.9 in
breadth-1) concentrator photovoltaic modules 1M are assembled
vertically and horizontally, except the center portion. When one
concentrator photovoltaic module 1M has a rated output of, for
example, about 100 W, the entirety of the concentrator photovoltaic
panel 1 has a rated output of about 6 kW.
On the rear surface side of the concentrator photovoltaic panel 1,
a driving device (not shown) is provided. By operating this driving
device, it is possible to cause the concentrator photovoltaic panel
1 to always face the direction of the sun.
FIG. 2 is a perspective view (partially cut out) showing an
enlarged view of one example of the concentrator photovoltaic
module (hereinafter, also simply referred to as "module") 1M. Three
directions orthogonal with one another are defined as X, Y, and Z,
as shown in FIG. 2.
In FIG. 2, the module 1M includes: a housing 11 formed in a vessel
shape and having a bottom surface 11a in parallel to the X-Y plane;
a plurality of flexible printed circuits 12 provided on the bottom
surface 11a; and a lens panel 13 (concentrating member) having a
rectangular shape (shown in a state of being partially cut out),
mounted on an end surface 15a of a wall part 15 standing from the
periphery of the bottom surface 11a, and closing an opening 11c of
the housing 11. The housing 11 is made of metal, for example, and
an aluminium alloy which is excellent in thermal conductivity in
particular is suitable therefor.
The lens panel 13 is a Fresnel lens array and is formed by
arranging, in a matrix shape, a plurality of (for example, 16 in
length.times.12 in breadth, 192 in total) Fresnel lenses 13f as
lens elements which concentrate sunlight. Each Fresnel lens 13f
forms a square effective concentration region. The lens panel 13
can be obtained by, for example, forming a silicone resin film on a
back surface (inside) of a glass plate used as a base material.
Each Fresnel lens 13f is formed on this silicone resin film. On the
external surface of the housing 11, a connector 14 for taking out
an output from the module 1M is provided.
Each flexible printed circuit 12 includes: a flexible substrate 16,
of a ribbon shape, on which a necessary conduction pattern is
provided; and a plurality of power generating element parts 21
provided on this flexible substrate 16. In the example shown in
FIG. 2, each flexible printed circuit 12 has eight power generating
element parts 21 mounted thereon. The flexible printed circuits 12
are arranged in a plurality of rows along the longitudinal
direction of the housing 11, and 24 flexible printed circuits 12
are arranged in total. Thus, the total number of the power
generating element parts 21 is 192 (24.times.8). That is, the
number of the power generating element parts 21 is the same as the
number of the Fresnel lenses 13f of the lens panel 13, and further,
the power generating element parts 21 are provided on the optical
axes of their corresponding Fresnel lenses 13f, respectively.
A Fresnel lens 13f and a power generating element part 21 provided
so as to correspond to each other form a concentrator photovoltaic
unit as an optical system basic unit for constructing the module 1M
described above.
FIG. 3 is a schematic diagram showing the concentrator photovoltaic
unit.
In FIG. 3, a photovoltaic unit (hereinafter, also simply referred
to as "unit") 20 includes the Fresnel lens 13f and the power
generating element part 21 described above.
The Fresnel lens 13f concentrates sunlight incident from an
incident surface 13f1, onto the power generating element part 21
provided so as to correspond thereto.
The power generating element part 21 includes: a ball lens 24; and
a solar cell 23 as a power generating element, the solar cell being
23 packaged by a resin frame 22 surrounding the periphery thereof
on the flexible substrate 16.
The ball lens 24 is a spherical lens formed by use of
borosilicate-based glass or quartz-based glass, for example. The
ball lens 24 is fixed to the resin frame 22 by adhesive bonding
using a silicone resin, an acrylic resin, or the like. Accordingly,
the ball lens 24 is fixed to the solar cell 23, with a slight gap
therebetween. This gap may be filled with the silicone resin, the
acrylic resin, or the like described above.
The ball lens 24 is provided so as to receive sunlight concentrated
by the Fresnel lens 13f, to lead the sunlight to the solar cell 23.
That is, the Fresnel lens 13f serves as a primary condenser lens,
and the ball lens 24 serves as a secondary condenser lens.
In this configuration, sunlight is concentrated by the Fresnel lens
13f being the primary condenser lens, then further concentrated by
the ball lens 24 being the secondary condenser lens, and then
emitted on the solar cell 23. Therefore, a large amount of light
energy is concentrated on the solar cell 23, and thus, power can be
generated at high efficiency.
The module 1M is configured to include a plurality of units 20
which each can generate power at high efficiency as described
above, and outputs power generated by each unit 20 from the
connector 14.
[2. Method for Producing Concentrator Photovoltaic Module]
Next, of the method for producing the module 1M, a method for
mounting the lens panel 13 of the module 1M onto the housing 11
will be described in particular.
As described above, each power generating element part 21 is
provided on the optical axis of its corresponding Fresnel lens 13f.
If the power generating element part 21 is greatly misaligned from
the optical axis of the Fresnel lens 13f, power generation
efficiency is reduced.
Therefore, when the lens panel 13 is to be fixed on the housing 11,
it is necessary to perform positional adjustment such that the
optical axis of each Fresnel lens 13f of the lens panel 13 is
accurately aligned with its corresponding power generating element
part 21 provided in the housing 11.
[2.1 Mounting Device]
FIG. 4 schematically shows one example of a mounting device for
mounting the lens panel 13 of the module 1M onto the housing 11. In
FIG. 4, three directions orthogonal with one another are defined as
X, Y, and Z, as shown in FIG. 4.
This mounting device 30 includes a base 31, a manipulator 32 for
moving the lens panel 13, and position specifying devices 33.
The mounting device 30 further includes: a controller 35 for
controlling the manipulator 32 and the position specifying devices
33; an operation section 36 for receiving an operation input made
by an operator of the mounting device 30; and a display section 37
for displaying images captured by the position specifying devices
33 at the time of positional adjustment as described later.
The base 31 is for fixing the housing 11. The base 31 fixes the
housing 11 whose opening 11c faces upward (Z direction), on an
upper surface 31a. The base 31 fixes the housing 11 such that the
bottom surface 11a of the housing 11 becomes horizontal (parallel
to the X-Y plane).
The manipulator 32 includes an arm part 32a, a suction cup part 32b
at the leading end of the arm part 32a, and an operation controller
32c which controls operations of these.
The suction cup part 32b, being a vacuum suction cup, strongly
adheres to the surface of the lens panel 13, and thus can hold the
lens panel 13.
The arm part 32a is the arm leading end of a six-axis vertical
articulated robot, for example, and can raise and lower the lens
panel 13 in the Z direction while maintaining the lens panel 13 in
a horizontal state along the X-Y plane. The atm part 32a can
arbitrarily move the lens panel 13 in X-Y directions while
maintaining the lens panel 13 in a horizontal state along the X-Y
plane. Further, the arm part 32a can also rotate the lens panel 13
about the central axis of the arm part 32a.
Thus, the manipulator 32 can move the lens panel 13 to above the
housing 11 fixed on the base 31 and place the lens panel 13 onto
the end surface 15a of the wall part 15 of the housing 11. Further,
the manipulator 32 can horizontally move the lens panel 13 placed
on the end surface 15a to adjust the position of the lens panel 13
relative to the housing 11 (the power generating element parts
21).
Operations of the arm part 32a and the suction cup part 32b are
controlled by the operation controller 32c. The operation
controller 32c controls operations of the arm part 32a and the
suction cup part 32b based on instruction from the controller
35.
The position specifying devices 33 are respectively arranged at
predetermined positions above the Fresnel lenses 13f respectively
positioned at four corners of the lens panel 13. Each position
specifying device 33 is fixed relative to the lens panel 13, so as
not to be displaced relatively from the lens panel 13. The position
specifying device 33 may not be fixed to the lens panel 13 as long
as the position specifying device 33 is fixed so as not to be
displaced relatively from the lens panel 13. For example, the
position specifying device 33 may be fixed to a part of the
manipulator 32 via a frame or the like.
In this manner, each position specifying device 33 is fixed so as
not to be displaced relatively from the lens panel 13 even when the
lens panel 13 is moved by the manipulator 32, and thus, the
position specifying device 33 is always at the same position
relative to the lens panel 13.
Each position specifying device 33 includes a plurality of laser
beam source parts and a camera part, and has a function of emitting
laser beams toward the Fresnel lens 13f and capturing an image of
the power generating element part 21 side through the Fresnel lens
13f. Details thereof will be described later.
The controller 35 has a function of comprehensively controlling
each position specifying device 33 and the manipulator 32 based on
an operation input made by the operator and received by the
operation section 36. The controller 35 aggregates data of images
captured by the position specifying devices 33, to provide the data
to the display section 37.
The operation section 36 is formed by an input device such as
operation keys or the like, and provides instruction based on an
operation input made by the operator, to the controller 35.
The display section 37 has a function of visually displaying the
data of captured images provided by the controller 35, and is
formed by an output device such as a liquid crystal display, a
touch panel, or the like. In a case where the display section 37 is
formed by a touch panel, the display section 37 can be configured
to also have the function of the operation section 36.
The operator can input necessary information to the operation
section 36 while confirming information displayed on the display
section 37, operate the mounting device 30 while confirming the
current state on the display section 37, and perform mounting of
the lens panel 13, including positional adjustment and the like of
the lens panel 13 described later.
Next, a method for mounting the lens panel 13 of the module 1M onto
the housing 11 by use of the mounting device 30 will be
described.
[2.2 Mounting Method]
First, as shown in FIG. 4, the housing 11 is fixed onto the upper
surface 31a of the base 31.
Next, the manipulator 32 is caused to hold the lens panel 13 so as
to be horizontal (parallel to the X-Y plane), and then is caused to
move the lens panel 13 to above the housing 11.
Then, the lens panel 13 is lowered to a position (a position in the
Z direction) where the height dimension between the lens panel 13
and the power generating element parts 21 on the bottom surface 11a
becomes a predetermined value set based on the focal length of the
lens panel 13 (the Fresnel lens 13f).
FIG. 5 shows a state where the lens panel 13 has been lowered by
the mounting device 30. As shown in FIG. 5, the lens panel 13 has
been lowered and is held by the manipulator 32 at the position
where the height dimension between the lens panel 13 and the power
generating element parts 21 on the bottom surface 11a is a
predetermined value as described above.
With respect to horizontal (the X-Y plane) directions, the lens
panel 13 is roughly positioned based on the shape of the opening
11c of the housing 11, and is held at a position where the lens
panel 13 closes the opening 11c of the housing 11.
At this time, the lens panel 13 is being held by the manipulator
32. Thus, the manipulator 32 can move the lens panel 13 in a
horizontal direction and in a rotation direction about the central
axis of the arm part 32a, while maintaining the horizontal state of
the lens panel 13.
Next, the position specifying devices 33 are disposed and fixed at
predetermined positions above the Fresnel lenses 13f which are
positioned at the four corners of the lens panel 13.
FIG. 6 schematically shows a configuration of the position
specifying device 33 disposed above the Fresnel lens 13f.
In FIG. 6, the position specifying device 33 includes a plurality
(four in the example shown) of laser beam source parts 40 and one
camera part 41.
The camera part 41 includes an image capturing device, such as: a
lens for concentrating light; a CCD (Charge Coupled Device) for
converting the light concentrated by the lens into an electric
signal; a CMOS (Complementary Metal-Oxide Semiconductor); and the
like. The camera part 41 is configured to capture an image of a
predetermined imaging range to generate captured image data, and to
continuously provide the captured image data to the controller 35
at a predetermined time interval.
The camera part 41 is disposed such that the imaging direction in
which the camera part 41 captures an image of the imaging range is
parallel to an optical axis S of the Fresnel lens 13f and such that
the center of the imaging range is at the optical axis point S1 on
the incident surface 13f1 of the Fresnel lens 13f. That is, the
camera part 41 is disposed such that the imaging direction thereof
is aligned with the optical axis S of the Fresnel lens 13f. Since
the Fresnel lens 13f is held in a horizontal state, the optical
axis S is parallel with the Z-axis direction.
Accordingly, the camera part 41 is configured to capture an image
of the power generating element part 21 side along the optical axis
S of the Fresnel lens 13f from the incident surface 13f1 side of
the Fresnel lens 13f.
Each laser beam source part 40 includes a semiconductor laser
device for emitting a laser beam of a predetermined wavelength, a
collimating lens for collimating this laser beam, and the like, and
emits collimated linear laser beam from an emission portion 40a
from which laser beam is emitted.
The four laser beam source parts 40 are arranged at the four
corners of the Fresnel lens 13E The laser beam source parts 40 are
arranged so as to emit linear laser beams in parallel to the
optical axis S (parallel to the Z-axis direction) respectively
toward the incident positions 42 at the four corners previously set
on the incident surface 13f1
Since the Fresnel lens 13f concentrates incident light toward the
focal point F of the Fresnel lens 13f, the linear laser beams
emitted by the respective laser beam source parts 40 and incident
on the respective incident positions 42 on the incident surface
13f1 still advance as linear laser beams also after passing the
Fresnel lens 13f, to be concentrated toward the focal point F.
FIG. 7A shows captured images obtained by the camera part 41 when
each laser beam source part 40 has emitted a linear laser beam, and
shows one example of a captured image when nothing is present on
the optical axis S of the Fresnel lens 13f.
Linear laser beams emitted toward the respective incident positions
42 at the four corners of the incident surface 13f1 of the Fresnel
lens 13f are concentrated by the Fresnel lens 13f toward the focal
point F (FIG. 6) of the Fresnel lens 13f.
At this time, each linear laser beam to be concentrated forms a
linear beam image along the optical path of the linear laser
beam.
Thus, as shown in FIG. 7A, in a captured image 50 obtained by the
camera part 41, there appear four captured portions 51 of beam
images, in which the linear beam images respectively formed by the
linear laser beams emitted from the portions corresponding to the
incident positions 42 are captured.
Since the linear laser beams are concentrated toward the focal
point F, the captured portions 51 of beam images also extend toward
the focal point F. Thus, the portion where the captured portions 51
of beam images cross each other at the center of the captured image
50 indicates the focal point F.
Here, the camera part 41 is disposed such that the imaging
direction when the camera part 41 captures an image of the imaging
range is parallel to the optical axis S of the Fresnel lens 13f and
such that the center of the imaging range is at the optical axis
point S1 on the incident surface 13f1 of the Fresnel lens 13f.
Therefore, the captured image 50 is an image, captured along the
optical axis S, of the portion around the focal point F where the
respective beam images are concentrated. That is, the portion where
the captured portions 51 of beam images cross each other in the
captured image 50 is the optical axis point S1, and indicates the
position on the X-Y plane of the focal point F.
Therefore, from the captured portions 51 of beam images on the
captured image 50, it is possible to recognize the position of the
optical axis of the Fresnel lens 13f on the horizontal plane (on
the X-Y plane).
In the present embodiment, the incident positions 42 are
respectively set at the four corners of the incident surface 13f1,
and thus, among the captured portions 51 of the beam images
specified in the captured image 50 obtained by the camera part 41,
at least one pair of captured portions 51 of beam images cross each
other at the optical axis point S1. For example, a captured portion
51a of first beam image crosses a captured portion 51b of second
beam image and a captured portion 51c of third beam image. The
captured portion 51b of second beam image crosses the captured
portion 51a of first beam image and a captured portion 51d of
fourth beam image.
By use of the captured image 50 which allows recognition of the
optical axis of the Fresnel lens 13f as described above, the
optical axis of the Fresnel lens 13f can be accurately aligned with
its corresponding power generating element part 21.
Now, the camera part 41 and the laser beam source parts 40, both
constituting the position specifying device 33, are arranged and
fixed at predetermined positions above the Fresnel lenses 13f which
are positioned at the four corners of the lens panel 13, and then,
the laser beam source parts 40 are respectively caused to emit
linear laser beams in parallel to the optical axis S (first
step).
Here, the position in the Z direction (the height dimension between
the lens panel 13 and the power generating element parts 21) of the
lens panel 13 (the Fresnel lenses 13f) is set based on the focal
length of the lens panel 13 (the Fresnel lenses 13f) as described
above.
In addition, the position on the X-Y plane of the lens panel 13 has
been roughly determined. Accordingly, near the focal point of each
Fresnel lens 13f, its corresponding power generating element part
21 is present.
In this state, when the laser beam source parts 40 are respectively
caused to emit linear laser beams, the linear laser beams are
concentrated on the focal point F of the Fresnel lens 13f as shown
in FIG. 6, thereby being concentrated toward the power generating
element part 21 which is present near the focal point F.
At this time, each camera part 41 can capture an image of the power
generating element part 21 and beam images respectively formed by
the linear laser beams being concentrated toward the power
generating element part 21.
Thus, next, each camera part 41 is caused to output the captured
image 50 of the power generating element part 21 and the beam
images respectively formed by the linear laser beams; and then, the
lens panel 13 is moved on the X-Y plane, based on the positional
relationship between the captured portions 51 of the beam images
and the captured portion of the corresponding power generating
element part 21 in the captured image 50 obtained by the camera
part 41, whereby positional adjustment between the lens panel 13
and the power generating element part 21 is performed (second
step).
In FIG. 7B shows one example of a captured image when the power
generating element part 21 is present near the focal point of the
Fresnel lens 13f, and shows a case where the optical axis S of the
Fresnel lens 13f is substantially aligned with the center of the
power generating element part 21.
In this case, the linear laser beams pass the ball lens 24 of the
power generating element part 21, to be concentrated on the focal
point near the center of the solar cell 23.
The captured image 50 shows a state where the captured portions 51
of the beam images having passed a captured portion 52 of the ball
lens 24 are gathering, while keeping their linear shapes, at one
point near the centers of the captured portion 52 of the ball lens
24 and a captured portion 53 of the solar cell 23.
The point where the captured portions 51 of the beam images are
gathering is the optical axis point S1, and indicates the position
on the X-Y plane of the focal point of the Fresnel lens 13f.
Thus, in the case of FIG. 7B, it is possible to determine that the
optical axis of the Fresnel lens 13f is located near the centers of
the ball lens 24 and the solar cell 23.
FIG. 7C shows the other example of a captured image when the power
generating element part 21 is present near the focal point of the
Fresnel lens 13f, and shows a case where the optical axis S of the
Fresnel lens 13f is not aligned with the center of the power
generating element part 21.
In such a case, the linear laser beams are not concentrated on the
focal point near the center of the solar cell 23, and in addition,
in some cases, do not pass the ball lens 24 of the power generating
element part 21, or are incident on the ball lens 24 from
unexpected positions, whereby distortion occurs in the beam
images.
Accordingly, in the captured image 50, the captured portions 51 of
the beam images appear in a distorted manner.
That is, as shown in FIG. 7C, when the captured portions 51 of the
beam images appear in a distorted manner, it is possible to
determine that the optical axis of the Fresnel lens 13f is not
located near the centers of the ball lens 24 and the solar cell
23.
The lens panel 13 is moved on the X-Y plane such that the captured
images 50 outputted by (the camera parts 41 of) the position
specifying devices 33 respectively arranged at the four corners of
the lens panel 13 are each in the state as shown in FIG. 7B as much
as possible.
FIG. 8 shows one example of an aspect where the captured images 50
respectively outputted by the position specifying devices 33 are
displayed on the display section 37.
The controller 35 controls the display section 37 such that four
captured images 50 respectively provided from the position
specifying devices 33 are arranged side by side so as to be
respectively displayed in four divided portions of a display screen
37a of the display section 37.
The operator can grasp the positional relationship between the beam
images of the respective linear laser beams and the power
generating element part 21 by viewing each captured image 50 being
an image at the time when the power generating element part 21 side
is seen along the optical axis S from the incident surface 13f1
side of the Fresnel lens 13f. Based on this positional
relationship, the operator can perform positional adjustment
between the lens panel 13 (the Fresnel lenses 13f) and the
corresponding power generating element parts 21.
In this case, by displaying the captured images 50 arranged side by
side, it is easy for the operator to grasp the position of the lens
panel 13 in the current state, and also easy for the operator to
perform operation of positional adjustment for moving the lens
panel 13 to an appropriate position.
Based on the respective four captured images 50, when the lens
panel 13 has been adjusted to a position which allows determination
that the optical axes of the four Fresnel lenses 13f have been
aligned with their corresponding power generating element parts 21
in an allowable range, the lens panel 13 is temporarily fixed to
the end surface 15a of the wall part 15 of the housing 11 with an
adhesive or the like.
Then, the housing 11 is sent to the next step, and in the next
step, the lens panel 13 is fixed to the housing 11 with a resin for
fixation.
Based on the respective four captured images 50, by adjusting the
optical axes of the four Fresnel lenses 13f so as to be aligned
with their corresponding power generating element parts 21 in an
allowable range, it is possible to attain accurate alignment at
least with respect to the positional relationship between the
optical axes of the Fresnel lenses 13f, at the four corners of the
lens panel 13, for which the position specifying devices 33 have
been set, and their corresponding power generating element parts
21.
When the positions of the four Fresnel lenses 13f are determined,
the position of the lens panel 13 relative to the housing 11 is
also determined. Thus, also with respect to the positional
relationship between the other Fresnel lenses 13f for which the
position specifying devices 33 are not set and their corresponding
power generating element parts 21, it is possible to consider that
the other Fresnel lenses 13f are aligned with their corresponding
power generating element parts 21 in the range of the accuracy of
the Fresnel lenses 13f formed in the lens panel 13 and the
arrangement accuracy of the power generating element parts 21
disposed in the housing 11.
As described above, according to the mounting method of the present
embodiment, it is possible to perform positional adjustment such
that the optical axis of each Fresnel lens 13f of the lens panel 13
is accurately aligned with its corresponding power generating
element part 21 provided in the housing 11.
In the above embodiment, a case has been described in which the
controller 35 displays the captured images 50 on the display
section 37. However, when the controller 35 has a function of
performing image processing on each captured image 50 and
generating positional information indicating the positional
relationship between the beam images of the linear laser beams and
the power generating element part 21, the controller 35 may be
configured to output and display this positional information on the
display section 37. In this case, based on the above positional
information, the operator can easily grasp the position of the lens
panel 13 and also easily perform operation of positional adjustment
for moving the lens panel 13 to an appropriate position.
[3. Effects]
The present embodiment is a method for producing the module 1M, the
module 1M including a large number of units 20 each including the
Fresnel lens 13f, the Fresnel lens 13f configured to concentrate
sunlight incident from the incident surface 13f1 thereof, onto the
power generating element part 21, the method including: a first
step of emitting linear laser beams in parallel to the optical axis
S of each of target Fresnel lenses 13f, respectively toward four
incident positions 42 previously set on the incident surface 13f1
thereof; and a second step of performing positional adjustment
between the lens panel 13 (Fresnel lenses 13f) and the power
generating element part 21, based on the positional relationship
between the power generating element part 21 and beam images
respectively formed by the linear laser beams having passed the
Fresnel lens 13f to be concentrated toward the focal point F of the
Fresnel lens 13f at a time when the beam images and the power
generating element part 21 are seen along the optical axis S from
the incident surface 13f1 side of the Fresnel lens 13f, wherein the
four incident positions 42 in the first step are set to positions
that allow at least one pair of beam images, among the beam images
at a time when the power generating element part 21 side is seen
along the optical axis S from the incident surface 13f1 side of the
Fresnel lens 13f, to be beam images of linear laser beams that
cross each other at the optical axis point S1 of the Fresnel lens
13f.
According to the above configuration, when the power generating
element part 21 side is seen though the captured image 50 along the
optical axis S from the incident surface 13f1 side of the Fresnel
lens 13f, beam images respectively formed by the linear laser beams
cross each other at the optical axis point S1 of the Fresnel lens
13f. Thus, the position of the optical axis S of the Fresnel lens
13f can be recognized.
Thus, when performing positional adjustment (second step) between
the lens panel 13 and the power generating element part 21 by
moving the lens panel 13 on the X-Y plane, it is possible to
perform positional adjustment based on the positional relationship
between the power generating element part 21 and the beam images
which allow recognition of the position of the optical axis S at a
time when the power generating element part 21 side is seen though
the captured image 50 along the optical axis S from the incident
surface 13f1 side of the Fresnel lens 13f. Thus, it is possible to
easily and accurately perform alignment between the Fresnel lens
13f and the power generating element part 21.
In the present embodiment, each power generating element part 21
includes the solar cell 23 as a power generating element and the
ball lens 24 as a secondary condenser lens. In this case, even if
the state where the captured portions 51 of the beam images cross
each other as shown in FIG. 7B is not clearly confirmed, alignment
between the Fresnel lens 13f and the power generating element part
21 can be performed based on the positional relationship between
(the captured portions 51 of) the beam images and (the captured
portion 52 of) the ball lens 24.
Also in a case of using a power generating element part not
including the ball lens 24 as in the power generating element part
21 of the present embodiment, it is possible to grasp the
positional relationship between the beam images and the power
generating element part by use of the captured image 50, and it is
possible to perform alignment between the Fresnel lens 13f and the
power generating element part 21 based on this positional
relationship.
[4. Modifications]
In the present embodiment, a case has been shown in which the
position specifying devices 33 are respectively arranged for the
four Fresnel lens 13f respectively positioned at the four corners
of the rectangular lens panel 13. However, if the position
specifying devices 33 are respectively arranged for at least two
Fresnel lenses 13f, and at each position specifying device 33,
alignment is performed between the optical axis S of the Fresnel
lens 13f and the power generating element part 21, the position of
the lens panel 13 can be specified on the horizontal plane (the X-Y
plane). Thus, when mounting the lens panel 13 onto the module 1M,
it is sufficient that the position specifying devices 33 are
respectively arranged for at least two Fresnel lenses 13f.
However, the greater the number of positions where the alignment is
performed for the lens panel 13, the higher the accuracy of the
alignment becomes. In addition, the greater the distance between
the positions at which the alignment is performed, the higher the
accuracy of the alignment becomes.
In this point, in the present embodiment, the position specifying
devices 33 are respectively arranged for the four Fresnel lenses
13f respectively positioned at the four corners of the rectangular
lens panel 13, and positional adjustment between the lens panel 13
and the power generating element parts 21 is performed. Thus,
alignment between the optical axes S of the Fresnel lenses 13F and
the power generating element parts 21 can be performed by use of
the Fresnel lenses 13f which are distanced from each other on the
lens panel 13, and thus, alignment between the lens panel 13 and
the power generating element parts 21 can be performed more
accurately.
As shown in FIG. 9A, the position specifying devices 33 may be
respectively arranged for four Fresnel lenses 13f positioned at
edge portions at the centers of the respective sides of the
rectangular lens panel 13.
Also in this case, alignment between the optical axes S of the
Fresnel lenses 13f and the power generating element parts 21 can be
performed by use of the Fresnel lenses 13f which are distanced from
each other on the lens panel 13, whereby alignment between the lens
panel 13 and the power generating element parts 21 can be performed
more accurately.
Further, as shown in FIG. 9B, a configuration may be employed in
which the position specifying devices 33 are respectively arranged
for the Fresnel lenses 13f respectively positioned at both ends of
one of the long sides of the rectangular lens panel 13, and the
position specifying device 33 is arranged for the Fresnel lens 13f
positioned at an edge portion at the center of the other of the
long sides of the rectangular lens panel 13.
In this case, three position specifying devices 33 are arranged in
total, but also in this case, the alignment is performed at the
Fresnel lenses 13f which are distanced from each other as much as
possible, and thus, accuracy of the alignment can be increased.
In the above embodiment, a case has been shown in which: each
position specifying device 33 includes four laser beam source parts
40; and the respective four laser beam source parts 40 are
configured to emit linear laser beams toward incident positions 42
respectively set at the four corners of the incident surface 13f1
of the Fresnel lens 13f. However, it is sufficient that each
position specifying device 33 includes at least two laser beam
source parts 40.
However, the incident positions 42 in this case need to be
positions that allow the captured portions 51 of beam images of one
pair of linear laser beams having passed one pair of incident
positions 42 in the captured image 50, to be captured portions of
beam images of linear laser beams that cross each other at the
optical axis point S1. This is because if the captured portions 51
of beam images of one pair of linear laser beams having passed one
pair of incident positions 42 in the captured image 50 cross each
other at the optical axis point S1, the position of the optical
axis S of the Fresnel lens 13f can be recognized.
For example, FIG. 10B shows a case where the incident positions 42
are respectively set at one pair of corner portions among four
corners of the incident surface 13f1 of the Fresnel lens 13f, the
pair of corner portions satisfying the relationship of being both
ends of the same side. In this case, the captured portion 51 of
beam images of one pair of linear laser beams having passed one
pair of incident positions 42 in the captured image 50 cross each
other at the optical axis point S1.
When one pair of incident positions 42 are provided on a diagonal
line that passes the optical axis S of the Fresnel lens 13f, the
beam images of one pair of linear laser beams in this case overlap
each other without crossing each other in the captured image 50,
and appear as one linear image that passes the optical axis point
S1. Thus, it becomes difficult to identify the optical axis point
S1.
In contrast to this, as shown in FIG. 10B, when the incident
positions 42 are respectively set at positions that allow the
captured portions 51 of beam images of one pair of linear laser
beams having passed one pair of incident positions 42 in the
captured image 50, to be captured portions of beam images of linear
laser beams that cross each other at the optical axis point S1, the
position of the optical axis S of the Fresnel lens 13f can be
assuredly recognized.
Alternatively, for example, as shown in FIG. 10A, three incident
positions 42 may be set with a central angle of 120 degrees
therebetween, about the optical axis point S1 of the Fresnel lens
13f. In this case, in the captured image 50, beam images of the
respective three linear laser beams appear so as to cross one
another.
In the above embodiment, the method for mounting the lens panel 13
regarding the module 1M which includes a large number of units 20
has been described. However, the mounting method can be applied to
a photovoltaic apparatus composed of a single unit 20.
[5. Others]
In the above embodiment, an exemplary case has been shown in which:
the operator of the mounting device 30 performs positional
adjustment between the lens panel 13 (the Fresnel lenses 13f) and
the corresponding power generating element parts 21 while
confirming the captured images 50 displayed on the display section
37. However, for example, based on the captured images 50
respectively provided from the position specifying devices 33, the
controller 35 may specify an optimum position, and provide the
manipulator 32 with positional information indicating the specified
position, thereby to control the manipulator 32.
In this case, the controller 35 generates positional information
indicating the positional relationship, grasped by performing image
processing on each captured image 50, between the power generating
element part 21 and the beam images respectively formed by the
linear laser beams having passed the Fresnel lens 13f to be
concentrated toward the focal point F thereof.
The manipulator 32 performs positional adjustment between the lens
panel 13 (the Fresnel lenses 13f) and the power generating element
parts 21 based on the above positional information.
Thus, the controller 35 and the manipulator 32 form a positional
adjustment section which performs positional adjustment between the
lens panel 13 (the Fresnel lenses 13f) and the power generating
element parts 21 based on the positional information indicating the
positional relationship, grasped through each captured image 50,
between the power generating element part 21 and the beam images
respectively formed by the linear laser beams having passed the
Fresnel lens 13f to be concentrated toward the focal point F.
In this case, the controller 35 may be configured by a computer
including a CPU, a storage device, and the like. In that case, the
function as the positional adjustment section is realized by a
computer program. In the storage device, a computer program for
realizing the function as the positional adjustment section is
stored in addition to programs for controlling each section.
This computer program is a computer program for causing a computer
to execute processes regarding production of a concentrator
photovoltaic unit, the concentrator photovoltaic unit including a
condenser lens configured to concentrate sunlight incident from an
incident surface thereof, onto a power generating element part, the
computer program causing the computer to execute: a step of causing
a plurality of laser beam sources to emit linear laser beams in
parallel to the optical axis of the condenser lens, respectively
toward a plurality of specific positions previously set on the
incident surface; and a positional adjustment step of performing
positional adjustment between the condenser lens and the power
generating element part, based on a captured image outputted by an
image capturing section configured to capture an image of the power
generating element part side along the optical axis from the
incident surface side of the condenser lens, wherein the plurality
of specific positions are set at positions that allow at least one
pair of beam images to be beam images of linear laser beams that
cross each other at the optical axis point of the condenser lens in
the captured image.
Also in the mounting device 30 having the above configuration,
alignment between the lens panel 13 (the Fresnel lens 131) and the
power generating element part 21 can be easily and accurately
performed.
[6. Conclusion]
The embodiment disclosed herein is to be considered in all respects
as illustrative and not restrictive. The scope of the present
invention is indicated by the appended claims rather than by the
foregoing meaning, and all changes that come within the meaning and
range of equivalency of the claims are therefore intended to be
embraced therein.
REFERENCE SIGNS LIST
1 concentrator photovoltaic panel
1M concentrator photovoltaic module
2 post
3 base
11 housing
11a bottom surface
11c opening
12 flexible printed circuit
13 lens panel
13f Fresnel lens
13f1 incident surface
14 connector
15 wall part
15a end surface
16 flexible substrate
20 unit
21 power generating element part
22 resin frame
23 solar cell
24 ball lens
30 mounting device
31 base
31a upper surface
32 manipulator
32a arm part
32b suction cup part
32c operation controller
33 position specifying device
35 controller
36 operation section
37 display section
37a display screen
40 laser beam source part
40a emission portion
41 camera part
42 incident position
50 captured image
51 captured portion
51a captured portion of first beam image
51b captured portion of second beam image
51c captured portion of third beam image
51d captured portion of fourth beam image
52 captured portion of ball lens
53 captured portion of solar cell
100 concentrator photovoltaic apparatus
F focal point
S optical axis
S1 optical axis point
* * * * *